Reel having deforming engagement of core to flange

ABSTRACT

An apparatus for supporting wound flexible media includes a reel core, a first flange and a second flange. The first flange comprises a flange body having a periphery, and further includes an outer rim extending axially outward and radially outward from the periphery with respect to the reel core. The reel core extends between said first flange and said second flange.

[0001] This application is a division of U.S. patent application Ser.No. 09/607,473, filed Jun. 30, 2000, which claims the benefit of U.S.Provisional Patent Application Serial No. 60/142,270, filed Jul. 2,1999.

FIELD OF THE INVENTION

[0002] The present invention relates generally to reels for supportingwound flexible media, and in particular, to reels having a core and atleast one attachable flange.

BACKGROUND OF THE INVENTION

[0003] Reels for supporting wound flexible media are employed to bothstore and facilitate the dispensing of wound media such as rope, wire,chain, and strings of parts. The essential elements of a reel includeits core, around which the flexible media is wound, and its flanges,which prevent the wound flexible media from migrating axially off of thecore.

[0004] Well-designed reels must combine a high strength to weight ratiowith low manufacturing cost. One reel design that has gained popularityfor certain applications includes a reel in which the core isconstructed of a pressed paperboard material and the flanges areconstructed of a composite or plastic material. The use of paper andplastic components, in general, provides a high strength to weight ratioand facilitates the use of relatively straightforward manufacturingtechniques. Another lightweight reel design consists of a pressedpaperboard core and corrugated paper flanges. While such all-paper reelsprovide significant economy and light weight, all-paper reels are notsuitable for certain medium to heavy duty applications because the paperflanges do not have the strength of plastic, wood, or steel flanges.Accordingly, for medium to heavy duty reel applications, plastic orcomposite flanges provide an advantageous combination ofmanufacturability, light weight, and strength.

[0005] Reels having composite or plastic flanges are relatively simpleto manufacture. The flanges may be formed using injection moldingtechniques. The flanges are then attached to the core. While themanufacturing process is relatively simple, the labor involved in thereel assembly process nevertheless contributes significantly to themanufacturing cost of the reel. One source of labor cost arises from theprocess of securing the flanges to the reel.

[0006] Flanges have been secured to reels using a number of methods. Theselection of an attachment mechanism must balance the need for a secureattachment with low manufacturing cost. The use of staples to attach aplastic flange to a paperboard hub is well-known, and is discussed, forexample, in U.S. Pat. No. 5,660,354 to Ripplinger. The drawbacks ofstapling include the labor involved with the application of the severalstaples that are necessary to provide a secure attachment between theflanges and the core.

[0007] Other known reel designs include nut and through-bolt assembliesthat secure the flanges to the core. These arrangements also require asignificant amount of labor in the assembly of the reel, and furtherincur the material costs of the steel nuts and bolts.

[0008] What is needed, therefore, is a method of and arrangement forattaching a flange to a core in a reel assembly that requires less laborthan the prior art arrangements, while still providing a secureattachment.

SUMMARY OF THE INVENTION

[0009] The present invention fulfills the above needs, as well asothers, by providing a flange that has features that deformingly engagea pliable end of the core to secure the core to the flange. Morespecifically, the flange includes an inward extending ridge and anoutward extending ridge that deformingly engage the pliable end of thecore. By deformingly engaging the pliable end using inward and outwardextending ridges, the pliable end of the core is deformed in opposingdirections, thereby securing the pliable end (and the core) to theflange. The resulting reel may thus be formed by advancing the core suchthat the pliable end advances between the inward and outward extendingridges. As a result, other securing mechanisms, such as bolts or staplesneed not be used.

[0010] An exemplary embodiment of the present invention includes a reelfor supporting wound flexible media that comprises a core, a firstflange and a second flange. The core has a first pliable end and asecond end, the first pliable end defining a first cross-sectionalshape. The first flange has an outer section and an inner section. Theouter section includes an inner rim, the inner rim including a radiallyinward extending ridge defining at least a portion of a peripherycorresponding substantially to the first cross-sectional shape andconfigured to deformingly engage the first pliable end. The innersection includes an outer rim, the outer rim including a radiallyoutward extending ridge defining at least a portion of a peripherycorresponding substantially to the first cross-sectional shape andconfigured to deformingly engage the first pliable end. The secondflange is coupled to the second end.

[0011] An exemplary method according to the present invention includes amethod of manufacturing a reel for supporting wound flexible media, thereel including a core having a first pliable end, the first pliable enddefining a first cross-sectional shape. The method includes a step ofdisposing at least a portion of a first flange on a support, the firstflange having an outer section and an inner section, the outer sectionincluding an inner rim, the inner rim including a radially inwardextending ridge having a periphery corresponding substantially to thefirst cross-sectional shape, and the inner section including an outerrim, the outer rim including a radially outward extending ridge having aperiphery corresponding substantially to the first cross-sectionalshape. The method further includes the step of advancing the core pastthe radially outward extending ridge and the radially inward extendingridge such that at least one of the radially outward extending ridge andthe radially inward extending ridge deformingly engage the first pliableend. Finally, the method includes the step of securing a second flangeto the core.

[0012] Accordingly, by employing a flange having inward and outwardextending ridges that deformingly engage a pliable end of a core, themethod and apparatus of the present invention forms a secure attachmentbetween the flange and the core without separate fasteners such as boltsor staples. Even if supplemental fasteners are used, the reel of thepresent invention provides a much more secure attachment through thedeforming engagement of the ridges and pliable end. In one embodiment,the inner and outer extending ridges are wedge-shaped such that theridges are tapered from the inside out in the axial direction. Thewedge-shaped ridges facilitate movement of the pliable end of the coreinto a position between the ridges, yet resist movement of the pliableend of the core back out of that position.

[0013] The above discussed features and advantages, as well as others,will become more readily apparent to those of ordinary skill in the artby reference to the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 shows a perspective view of a first exemplary embodiment ofa reel according to the present invention;

[0015]FIG. 2 shows a cutaway cross-sectional view of a flange of thereel of FIG. 1 wherein the flange is removed from the core of the reel;

[0016]FIG. 3 shows a cutaway cross-sectional view of the outer sectionof the flange of FIG. 2 wherein the outer section is removed from theinner section of the flange;

[0017]FIG. 4 shows a cutaway cross-sectional view of an inner section ofthe flange of FIG. 2 wherein the inner section is removed from the outersection of the flange;

[0018]FIG. 5 shows a plan view of the outer section of the flange ofFIG. 2 wherein the outer section is removed from the inner section ofthe flange;

[0019]FIG. 6 shows a plan view of the inner section of the flange ofFIG. 2 wherein the inner section is removed from the outer section ofthe flange

[0020]FIG. 7 shows an enlarged, partial, cutaway cross-sectional view ofthe reel of FIG. 1.

[0021]FIG. 8 shows a perspective view of a second exemplary embodimentof a reel according to the present invention;

[0022]FIG. 9 shows a cutaway cross-sectional view of a flange of thereel of FIG. 2 wherein the flange is removed from the core of the reel;

[0023]FIG. 10 shows a plan view of the flange of FIG. 2;

[0024]FIG. 11 shows a fragmentary plan view of a third exemplaryembodiment of a reel according to the present invention, with the coreshown in cross section;

[0025]FIG. 12 shows an exploded view of the reel of FIG. 11;

[0026]FIG. 13 shows a top plan view of a plug of the reel of FIG. 11;

[0027]FIG. 14 shows a fragmentary plan view of a flange fin of the reelof FIG. 11;

[0028]FIG. 15 shows a plan view of the flange fin of FIG. 14 taken alongview 15-15 of FIG. 14;

[0029]FIG. 16 shows a fragmentary plan view of a fourth exemplaryembodiment of a reel according to the present invention with the coreshown in cross section; and

[0030]FIG. 17 shows an exploded fragmentary view of the reel of FIG. 16.

DETAILED DESCRIPTION

[0031]FIG. 1 shows an exemplary embodiment of a reel 10 according to thepresent invention which includes a core 12, a first flange 14 and asecond flange 16. The core 12 has a first pliable end 13 (see FIG. 7)and a second end 15. The first pliable end 13 has a firstcross-sectional shape, which in the exemplary embodiment discussedherein is a circular cross-sectional shape. It is noted that the core 12typically, but not necessarily, has a substantially uniformcross-sectional shape. In the exemplary embodiment described herein, thecore 12 comprises a pressed paperboard tube.

[0032] As shown in FIGS. 1 and 2, the first flange 14 includes an outersection 18 (see also FIG. 3) and an inner section 20 (see also FIG. 4).The outer section 18 and the inner section 20 are preferably molded of aplastic or composite material. However, metal and other rigid materialsmay be used while still retaining many of the advantages of the presentinvention. In the exemplary embodiment of FIGS. 1-7, the outer section18 and the inner section 20 are separate, distinct structures.

[0033] With reference to FIGS. 1, 2, and 3, the outer section 18includes a main retaining member 22, an outer rim 24, and an inner rim26. The retaining member 22 provides the structure to support and retainwound flexible media when it is loaded onto the core 12. The outer rim24 extends axially from the outer periphery of the main retaining member22 and the inner rim 26 extends axially from the inner periphery of themain retaining member 22.

[0034] The shape of the inner rim 26 corresponds to the firstcross-sectional shape, i.e., the shape of the first pliable end 13 ofthe core 12. The inner rim 26 has a shape that corresponds to the shapeof the first pliable end 13 because, as discussed more fully below, theinner rim 26 forms a boundary of a channel in which the first pliableend 13 is retained. (See FIG. 7). In the exemplary embodiment describedherein, the main retaining member 22 defines an annulus such that theouter rim 24 and the inner rim 26 are substantially circular. It will benoted however, that the exact shapes of the outer rim 24 and theretaining member 22 are a matter of design choice.

[0035] The inner rim 26 includes a radially inward extending ridge 28defining at least a portion of a periphery corresponding substantiallyto the first cross-sectional shape. As shown in FIG. 7, the radiallyinward extending ridge 28 is configured to deformingly engage the firstpliable end 13 of the core 12. In other words, when the reel 10 isassembled, the first pliable end 13 is deformed around the radiallyinward extending ridge 28.

[0036] The radially extending ridge 28, while generally defining aperiphery corresponding to the first cross-sectional shape, may comprisebroken segments of a theoretically continuous periphery, such as isshown in FIG. 3. In particular, drive holes, feeder holes, and/or otherdesign features of the flange 14, which are known to those of ordinaryskill in the art, create breaks, such as the breaks 30, in the peripherydefined by the radially inward extending ridge 28. Such breaks 30typically also interrupt the continuity of the inner rim 26 itself.

[0037] The cross section of the radially inward extending ridge 28 ispreferably tapered, or wedge-shaped, to assist in assembly of the reel10. In particular, as discussed below the wedge shape of the radiallyinward extending ridge 28 facilitates movement of the core 12 in thedirection B, as is needed to assemble the reel 10, and inhibits movementof the core 12 in the direction A, thereby securing the core 12 toflange 14.

[0038] To this end, as shown in FIG. 3, the radially inward extendingridge 28 includes a first face 40 and a second face 42. The first face40 extends from the inner rim 26 at a first angle with respect to theradial plane. The second face 42 extends from the inner rim 26 at asecond angle with respect to the radial plane. As shown in FIGS. 3 and7, the first face 40 is axially inward from the second face 42 withrespect to the core 12. The first angle is greater than the secondangle, thereby defining the wedge-shape of the radially inward extendingridge 28. Thus, the second face 42 extends in a direction that has lessof an axial component than the direction in which the first face 40extends. As a result, the first face 40 provides a more tapered axialpath interruption than the second face 42. Because the axial pathinterruption introduced by the first face is more tapered, the core 12is more easily advanced in the direction B (from the first face 40 tothe second face 42), as when the reel 10 is assembled, than in thedirection A (from the second face 42 to the first face 40), as when thereel 10 would be broken apart.

[0039] The inner section 20 comprises a hub-like structure defined by amain body 32, and arbor rim 34, and an outer rim 36. The arbor rim 34defines an arbor opening 35 in the inner section 20. The arbor opening35 cooperates with a like arbor opening on the other flange 16 of thereel 10 to allow rotation of the reel 10 about a central axle, notshown.

[0040] The main body 32 in the exemplary embodiment is generallydisk-shaped, and may include typical features of a reel hub, such asdrive holes 37, support ribs 39 and/or other features. In accordancewith the present invention, the outer rim 36 includes a radially outwardextending ridge 38 defining at least a part of a periphery correspondingsubstantially to the first cross-sectional shape. The radially outwardextending ridge 38 is thus configured to deformingly engage the firstpliable end 13 (see FIG. 7).

[0041] Similar to the radially inward extending ridge 28, the radiallyoutward extending ridge 38 is preferably wedge-shaped. To this end, theradially outward extending ridge 38 includes a third face 44 and afourth face 46. The third face 44 is axially inward from the fourth face46 with respect to the core 12 (see FIG. 7). The third face 44 extendsfrom the outer rim 36 at a third angle with respect to the radial planeand the fourth face 46 extends from the outer rim 36 at a fourth anglewith respect to the radial plane. Similar to the first angle of thefirst face 40 and the second angle of the second face 42, the thirdangle is greater than the fourth angle. Because the third angle isgreater than the fourth angle, the core 12 is more easily advanced inthe direction B than in the direction A. As a result, less force isrequired to assemble the reel 10 than to break apart the reel 10.

[0042] As shown in FIG. 7 the radially inward extending ridge 28 and theradially outward extending ridge 38 deform the core 12 in opposingdirections, thereby grasping the core 12 therebetween. The core 12resists movement in the direction A by any number of physicalcharacteristics.

[0043] For example, the wedge-shaped nature of the first face 40 and thesecond face 42, as well as the wedge-shaped nature of the third face 44and the fourth face 46 may create in some embodiments a barbingengagement between the core 12 and the ridges 28 and 38. For example, ifthe second angle and the fourth angle are substantially zero, then theridges 28 and 38 may provide a barbing engagement with the core 12. Insuch embodiments the ridges 28 and 38 tend to dig into the material ofthe core 12, for example, paperboard, to help inhibit movement of thecore 12 in the direction A with respect to the flange 14. The deformingengagement of the core 12 in opposing directions by the ridges 28 and 38enhance the digging retention force.

[0044] Another physical characteristic that may help inhibit movement ofthe core 12 in the direction A arises from the configuration of theouter section 18 and the inner section 20 as separate distinctcomponents. Because the outer section 18 and the inner section 20 areseparate components, they are capable of relative axial movement withrespect to each other. The primary force that would cause relative axialmovement of the outer section 18 and the inner section 20 is the axiallyoutward force of the payload (not shown) against the retaining member.Such force tends to urge the outer section 18 in the direction Arelative to the inner section 20. As the outer section 18 is urged inthe direction A, the ridges 28 and 38 clamp or pinch the first pliableend 13. Such clamping and pinching further inhibits axial movement ofthe core 12 in the direction A. Accordingly, the use of an outer section18 and an inner section 20 that are capable of relative movement mayprovide enhanced integrity of the core 12 to the flange 14.

[0045] It is noted that while only the first flange 14 is discussedabove in detail, the second flange 16 may suitably have the samestructure.

[0046] Thus, the above described embodiment of the present inventionprovides an advantage of a secure interconnection between the flanges 14and 16 resulting from the deformation of the first pliable end 13 of thecore 12 by the opposing ridges 28 and 38. Another advantage of theinvention is the reduced labor requirements in manufacturing the reel10. The combination of the provision of a secure attachment with reducedlabor requirements desirably reduces the relative cost of the reel 10 ascompared to reels of similar strength using staples or the like.

[0047] The reduced labor requirements discussed above will become morereadily apparent by reference to the method of manufacturing the reel10, discussed below. However, it will be appreciated that at least someof the advantages of the present invention may be realized even if othermethods of manufacture are implemented.

[0048] In any event, to manufacture the reel 10 in accordance with afirst exemplary method according to the present invention, the outersection 18 and the inner section 20 of the flange 14 are formed as twoseparate pieces. To this end, the outer section 18 and the inner section20 are preferably molded as a single piece using single mold (notshown). To this end, the mold design may include breakaway connectors 50that allow the outer section 18 and the inner section 20 to be separatedafter molding. Such molding techniques are well-known. Alternatively,the outer section 18 and the inner section 20 of the reel may beseparately molded.

[0049] In accordance with the method, once the outer section 18 and theinner section 20 are formed, the outer section 18 is preferably disposedon a support and the first pliable end 13 of the core 12 is advancedinto the outer section 18, or in other words, past the radially inwardextending ridge 28. The inner section 20 is thereafter inserted into thefirst pliable end 13 of the core 12, such that, in a relative manner,the first pliable end 13 is advanced past the radially outward extendingridge 38.

[0050] The second flange 16 may suitably be assembled to the core 12 inthe same manner.

[0051] It will be appreciated that those of ordinary skill in the artmay modify the above exemplary method such that the core 12 is securedto the first flange 14 and the second flange 16 contemporaneously. Forexample, a hydraulic or robotic fixture may be configured to secure thecore 12 to both flanges 14 and 16 contemporaneously. Such a modificationcan shorten the production cycle, but can require more costly equipment.

[0052] In an alternative embodiment of the present invention, theflanges are constructed of a single, integral member. FIGS. 8 through 10show such an embodiment of the present invention. While use of singlepiece flanges eliminates some of the binding or pinching phenomenaassociated with use of separately movable flange sections (e.g. innersection 20 and outer section 18 discussed above), the single pieceflange design has other structural advantages inherent to a single piecedesign. For example, it has been observed that the single piece flangedesign can perform better in drop tests.

[0053]FIG. 8 shows an exemplary embodiment of a reel 110 according tothe present invention which includes a core 112, a first flange 114 anda second flange 116. The core 112 may suitably have the same structureas the core 12 of FIG. 1. Accordingly, the core 112 has a first pliableend and a second end similar to the first pliable end 13 and second end15 of FIGS. 1 and 7. Similar to the reel 10 of FIG. 1, the first pliableend 113 has a first cross-sectional shape, which in the exemplaryembodiment discussed herein is a circular cross-sectional shape.

[0054] Referring generally to FIGS. 8-10, the first flange 114 includesan outer section 118 and an inner section 120. The outer section 118 andthe inner section 120 are preferably molded of a plastic or compositematerial. However, metal and other rigid materials may be used whilestill retaining many of the advantages of the present invention. In theexemplary embodiment of FIGS. 8-10, the outer section 118 and the innersection 120 are formed as integral structures.

[0055] The outer section 118 includes a main retaining member 122, anouter rim 124, and an inner rim 126. The retaining member 122 providesthe structure to support and retain wound flexible media when it isloaded onto the core 112. The outer rim 124 in the exemplary embodimentdescribed herein constitutes a tapered outer rim 124. The tapered outerrim extends both axially and radially from the outer periphery of theretaining member 122. In particular, the tapered outer rim 124 has anintersecting circumference 124 a that intersects the outer periphery ofthe retaining member 122 and extends radially and axially from thatpoint to an end circumference 124 b. Because it extends both axially andradially, as opposed to substantially only radially like the outer rim24 of the embodiment of FIGS. 1-7, the tapered outer rim 24 providesadditional advantages.

[0056] In particular, reels are preferably designed to withstand somedegree of mishandling, including the impact from being dropped. To thisend, plastic reel flanges often include reinforcement ribs or the like.For example, the retaining member 122 includes a plurality ofreinforcement ribs 123. However, a loaded reel, including those thatemploy reinforced plastic flanges, will fail if dropped from at or abovesome height limit that may be measured. Reels having non-tapered outerrims, such as for example, the reel 10 described above, often exhibitfailure modes in which a fracture propagates through much or all of theradius of the retaining member 22 to the core 12. Such a failure mode isparticularly undesirable because the payload may be difficult to payout, or may become damaged during pay out, from a heavily fracturedretaining member 22.

[0057] The tapered outer rim 124 of the reel 110 of FIGS. 8-10, however,provides for a more advantageous failure mode. In particular, if thereel 110 is dropped, then the impact forces are focussed on the endcircumference 124 b of the tapered outer rim 124 (or, depending on thetilt of the reel, the end circumference of the tapered outer rim of thesecond flange 116. Because the impact forces are focussed on the endcircumference 124 b, a torque force is generated about the moment armdefined by the tapered outer rim. These torque forces tend to cause theflange 114 to fail at the intersecting circumference 124 a. In otherwords, part of the tapered outer rim 124 tends to snap off. It has beenobserved that failures at the intersecting circumference 124 a due tothe torque forces on the end circumference 124 b tend to remain isolatednear the outer circumference of the flange 114. In other words,fractures resulting from such failures have less of a tendency topropagate toward the center of the flange 114. The failures have less ofa tendency to propagate because when the tapered outer rim 124 snapsoff, it absorbs much of the impact energy.

[0058] By contrast, flanges with non-tapered outer rims are more likelyto absorb impacts closer to the intersection of the outer rim and theretaining member. Such impacts do not generate the same torque forcesabout the moment armed formed by the outer rim. As a result, the impactforces are not as likely to cause the rim itself to snap off and thusabsorb the impact energy. The unabsorbed impact energy is thus morelikely to cause fractures that extend well inward from the outer edge ofthe flange.

[0059] Accordingly, the rim 124 according to the present invention,which extends both axially and radially from the flange 114, assists inreducing the severity of impact failures by reducing the tendency ofimpact failures to tend to propagate toward the center of the flange. Itis noted that it the rim does not necessarily have to have the shape asshown, extending in a linear fashion between the intersectingcircumference 124 a and the outer circumference 124 b. Alternativeembodiments that extend in a step-wise or arcuate manner may beemployed, provided that such embodiments nevertheless employ a rim thatextends both axially and radially away from the end of the flange.

[0060] Referring again to the general description of the flange 114, theshape of the inner rim 126 corresponds to the first cross-sectionalshape, i.e., the shape of the first pliable end of the core 112. Theinner rim 126 has a shape the corresponds to the shape of the firstpliable end 113 because, similar to the inner rim 26 of the embodimentof FIGS. 1-7, the inner rim 126 forms a boundary of a channel 113 inwhich the first pliable end is retained.

[0061] The inner rim 126 includes a radially inward extending ridge 128defining at least a portion of a periphery corresponding substantiallyto the first cross-sectional shape. As with the embodiment of FIGS. 1-7,the radially inward extending ridge 128 is configured to deforminglyengage the first pliable end of the core 112. In other words, when thereel 110 is assembled, the first pliable end is deformed around theradially inward extending ridge 128. It is noted that as with the ridge28, the radially extending ridge 128 may actually comprise brokensegments of a theoretically continuous periphery.

[0062] The cross section of the radially inward extending ridge 128 ispreferably tapered, or wedge-shaped, to assist in assembly of the reel110. To this end, as shown in FIG. 9, the radially inward extendingridge 128 has a structure substantially identical to the radially inwardextending ridge 28 of the embodiment of FIGS. 1-7, discussed above.

[0063] The inner section 120 comprises a hub-like structure defined by amain body 132, and arbor rim 134, and an outer rim 136. The arbor rim134 defines an arbor opening 135 in the inner section 120. The arboropening 135 cooperates with a like arbor opening on the other flange 116of the reel 110 to allow rotation of the reel 110 about a central axle,not shown.

[0064] The main body 132 in the exemplary embodiment is generallydisk-shaped, and may include typical features of a reel hub, such asdrive holes 137, support ribs 139 and/or other features. In accordancewith the present invention, the outer rim 136 includes a radiallyoutward extending ridge 138 defining at least a part of a peripherycorresponding substantially to the first cross-sectional shape. Theradially outward extending ridge 138 is thus configured to deforminglyengage the first pliable end of the core 112.

[0065] Similar to the radially inward extending ridge 128, the radiallyoutward extending ridge 138 is preferably wedge-shaped. To this end, theradially outward extending ridge 138 is substantially identical instructure to the radially outward extending ridge 38 of FIGS. 2, 4, 7.

[0066] In general, the radially inward extending ridge 128 and theradially outward extending ridge 138 deform the core 112 in opposingdirections, thereby grasping the core 112 therebetween. The core 112resists movement in the direction A by any number of physicalcharacteristics, including friction. The deforming of the core 112 mayor may not involve actually penetrating the surface of the core.

[0067] The embodiment of FIGS. 8 through 10 thus provides many of thesame advantages as those associated with the embodiment of FIGS. 1through 7. However, the use of a single, unitary flange design in thereel 110 may reduce manufacturing costs by reducing the number of stepsrequired for assembly. However, the embodiment wherein the flange is atwo-part design comprising an inner section and a separate outer sectionsuch as shown in FIGS. 1 through 7 may be capable of greater flangeretention strength due to the relative movement that is possible betweenthe two sections.

[0068] In any event, an exemplary method of manufacturing the reel 110is provided herebelow. The flanges 114 and 116 are first generated. Tothis end, the outer section 118 and the inner section 120 of the firstflange 114 are injection molded as a single piece. The second flange 116is preferably generated in the same manner. In the exemplary methoddescribed herein, the outer section 18 and the inner section 20 of thefirst flange 14 are molded as a single connected piece. Alternatively,if metal flanges are used, normal metal forming techniques may beemployed.

[0069] After the first flange 114 is generated, the first flange 114 ispreferably disposed on a support, not shown. Then, the core 112 isadvanced past the radially inward extending ridge 128 and the radiallyoutward extending ridge 138 such that at least one of the radiallyinward extending ridge 128 and the radially outward extending ridge 138deformingly engage the first pliable end 113. The second flange 116 maysuitably be assembled to the core 112 in the same way.

[0070] FIGS. 11-15 show a third embodiment of a flange 214 according tothe present invention. The flange 214 may readily replace the flange 14of the reel 10 in FIG. 1. The flange 214 has a particularly secureattachment to the core. As shown in FIGS. 11, 12, and 13, the flange 214includes a flange body 216, a plurality of flange fins 218, and a plug220.

[0071] In particular, FIG. 11 shows the flange 214 assembled onto thecore 12. The flange 214 is shown in a side plan view with hiddenfeatures shown as dashed lines. The core 12 is shown as a partialsection. FIG. 12 shows the flange 214 and the core 12 in a view similarto FIG. 11. However, in FIG. 12, the plug 220 is separated from theflange body 216 and flange fins 218, and the core 12 is separated fromthe all of the components of the flange 214. FIG. 13 shows a top planview of the plug 220.

[0072] The plurality of flange fins 218 are secured to the flange body216 and are preferably integrally molded therewith. FIGS. 14 and 15 showin further detail a flange fin 218 apart from the remainder of theflange 214. The flange fin 218 includes a rib 222 that is secured on afirst end 223 to the flange body 216 (see FIGS. 11 and 12) and extendsaxially from the flange body 216. The rib 222 further extends radiallyto a position 224 at which the core 12 will roughly align. Radiallyinward from the position 224, the flange fin 218 in the exemplaryembodiment includes an axially inward extension 226. The axially inwardextension 226 further defines a wedge-shaped ridge 227 that isconfigured to engage, and preferably to deformingly engage, an innersurface of the core 12. (See FIG. 11). The axially inward extension 226further includes side barbs 228.

[0073] The flange body 216 may suitably include the main features ofeither of the outer sections 18 and 118 of the embodiments describedfurther above. However, the flange body 216 includes the followingdifferences. While the flange body 216 includes an inner rim 230 havinga radially inward extending ridge 232, the inner rim 230 furtherincludes an annular channel 234 for receiving the deformed end of thecore 12. Moreover, secured to the flange body 216 are a plurality offlange fins 218 as described above. The axially inward extensions 226 ofthe flange fins 218, which extend radially inward of the position 224,align with extension slots 236 in the plug 220 (See FIG. 13).

[0074] The plug 220 has a cross sectional shape with respect to the topview that corresponds to the cross section of the core 12. Thus, forexample, the plug 220 has a generally circular shape in the embodimentdescribed herein. However, the plug 220 has a diameter that tapersinward from top to bottom. The outer diameter at the top of the plug 220preferably exceeds the inner diameter of the core 12. The portion of theplug 220 near the top thereby forms a radially outward extending ridge238 that deformingly engages the core 12. (See FIG. 11). In fact, whenthe plug 220 is inserted, the radially outward extending ridge 238forces the pliable end of the core 12 into the annular channel 234.

[0075] Moreover, when the plug 220 is inserted, the plug 220 is retainedin position (as shown in FIG. 11) in part by the side barbs 228. Inparticular, the side barbs 228 engage the top of the plug 220 to assistin axially retaining the plug 220 from migrating axially out of theflange 214. in position as shown in FIG. 11.

[0076] It is noted that in the above embodiment, the outer section isthe flange body 214 and the inner section may be thought of as the plug220 and/or the axially inward extensions 226 of the flange fins 218.

[0077]FIGS. 16 and 17 show yet another alternative of a flange 314 foruse in a reel according to the present invention. The flange 314 isidentical to the flange 214 except that the flange 314 has a supportring 316 that extends in a substantially annular manner between thewedge-shaped ridges 337 of the axially inward extensions 326 of theflange fins 318. Preferably, the support ring 316 is configured suchthat insertion of the plug 320 of the flange 314 urges at least a partof the support ring 316 radially outward to engage and/or deforminglyengage the inner surface of the core 12. (See FIG. 16).

[0078] To allow the support ring 316 to expand radially outward, variousimplementations may be used. First, the support ring 316 may actuallyform a segmented ring defined by a plurality of arc segments. In such acase, the bottom portion 322 of the plug 320, which has an outerdiameter greater than the inner diameter of the support ring, causeseach of the arc segments to bend radially outward into the inner surfaceof the core 12. In other implementations, the support ring 316 may forma continuous ring. For example, in one implementation, the bottomportion 322 of the plug 320 is non-circular (or more generally, does notcoincide completely with the shape of the support ring 316), but insteadhas one or more areas in which the diameter of the bottom portion 322exceeds the support ring 316, and one or more compensation areas inwhich the diameter of the bottom portion 322 is less than the supportring 316. Thus, when the plug 320 is inserted, the bottom portion 322urges certain portions of the support ring 316 radially outward into theinner surface of the core 12 while allowing other portions of thesupport ring 316 to collapse or cord off to make the necessary slack. Inyet another implementation, the bottom portion 322 of the plug 320 isgenerally the same shape as the support ring 316 and has a greaterdiameter in order to force the support ring 316 radially outward in alldirections. To allow the support ring 316 to move radially outward inall directions, the support ring 316 is preferably constructed of amaterial that has some flexibility/stretchability to it. One suitablematerial would be an olefin material.

[0079] The support ring 316 may include a plurality of bumps, detents orridges, not shown that engage the inner surface of the core 12 to assistin preventing rotation of the core 12 with respect to the flange 314.The support ring 316 preferably has a wedge-shaped profile such that itacts as an annular extension of the wedge-shaped ridges 337 of theaxially inward extensions 326 of the flange fins 318. In any event, theuse of the support ring 316 helps further secure the core 12 to theflange 314, and further prevents rotation of the core 12 with respect tothe flange 314.

[0080] It will be appreciated that the above described embodiments aremerely exemplary, and that those of ordinary skill in the art mayreadily devise their own implementations that incorporate the principlesof the present invention and fall within the spirit and scope thereof.For example, the shapes and signs of the outer section and inner sectionof the flange according to the present invention may readily be modifiedwithout departing from the spirit of the invention, as long as the innerand outer sections feature opposing ridges that deformingly engage apliable end of a core.

[0081] Moreover, it is noted that the inner rim 26 of the outer section18 of the first flange 14 of FIG. 1 need not necessarily be the radiallyinner most part of the outer section. It is contemplated that the outersection 18 could include an annular overhang that extends radiallyinward over portions of the inner section 20. Likewise, the innersection 20 could conceivably include an overhang that extends radiallyoutward from the outer rim 36 over portions of the outer section 18.

[0082] It is also possible that for certain heavy duty applications,staples or other fasteners may be used to reinforce the attachmentbetween the flange and the core according to the present invention. Suchan embodiment may still realize some of the advantages of the presentinvention by potentially reducing the number of such fasteners requiredto achieve the same strength attachment as that provided by a reel thatdoes not incorporate the deformingly engaging ridges of the presentinvention.

We claim:
 1. An apparatus for supporting wound flexible mediacomprising: a reel core; a first flange comprising a flange body havinga periphery, the first flange further including an outer rim extendingaxially outward and radially outward from the periphery with respect tothe reel core; a second flange; and wherein the reel core extendsbetween said first flange and said second flange.
 2. The apparatus ofclaim 1 wherein said second flange comprises a second flange body havinga second periphery, the second flange further including a second outerrim extending axially outward and radially outward from the secondperiphery with respect to the reel core.
 3. The apparatus of claim 1wherein said first flange is constructed of plastic.
 4. The apparatus ofclaim 1 wherein the flange body includes a load bearing portion of thefirst flange.
 5. The apparatus of claim 4 wherein the periphery of theflange body further comprises a periphery of the load bearing portion.6. The apparatus of claim 1 wherein said first flange and said secondflange are generally disk shaped.
 7. The apparatus of claim 1 whereinsaid reel core is cylindrically shaped.
 8. The apparatus of claim 1wherein said reel core is removably secured to said first flange andsaid reel core is removably secured to said second flange.
 9. Theapparatus of claim 1 wherein the reel core includes a first pliable endand a second end, the first pliable end defining a first cross-sectionalshape; the first flange includes an outer section and an inner section,the outer section including an inner rim, the inner rim including aradially inward extending ridge defining at least a portion of a firstperiphery corresponding substantially to the first cross-sectional shapeand configured to deformingly engage the first pliable end, and theinner section including an outer rim, the outer rim including a radiallyoutward extending ridge defining at least a portion of a secondperiphery corresponding substantially to the first cross-sectional shapeand configured to deformingly engage the first pliable end.
 10. A flangefor use in a reel having first and second flanges attached to a reelcore, the flange comprising a load bearing section; an outer rimoperably coupled to a portion of the flange radially outward of the loadbearing section, the outer rim including an intersecting circumferenceadjacent the portion of the flange and end circumference, the outer rimextending radially outward and axially outward from the intersectingcircumference to the end circumference.
 11. The flange of claim 10wherein intersecting circumference defines an outer periphery of theload bearing section.
 12. The flange of claim 10 wherein the outer rimextends radially outward and axially outward from the intersectingcircumference to the end circumference in a linear manner.
 13. Theflange of claim 10 wherein said flange is constructed of plastic. 14.The flange of claim 10 wherein said first flange and said second flangeare generally disk shaped.
 15. The flange of claim 10 wherein saidflange includes an outer section and an inner section, the outer sectionincluding an inner rim, the inner rim including a radially inwardextending ridge defining at least a portion of a first peripherycorresponding substantially to the first cross-sectional shape andconfigured to deformingly engage a first pliable end of a reel core, andthe inner section including an outer rim, the outer rim including aradially outward extending ridge defining at least a portion of a secondperiphery corresponding substantially to the first cross-sectional shapeand configured to deformingly engage the first pliable end.
 16. Theflange of claim 10 wherein the load bearing section includes a pluralityof radially extending ribs.
 17. A flange for use in a reel having firstand second flanges attached to a reel core, the flange comprising a loadbearing section; and an outer rim operably extending radially outwardand axially outward from the load bearing section.
 18. The flange ofclaim 17 wherein the flange is constructed of plastic.
 19. The flange ofclaim 17 wherein the load bearing section and the outer rim areintegrally molded.
 20. The flange of claim 17 wherein the load bearingsection includes a plurality of radially extending ribs.